Thermal management systems and methods with heating component

ABSTRACT

A vehicle has a thermal management system that comprises an electric power source loop comprising at least one battery. The thermal management system further comprises a heating component thermally coupled to the electric power source loop. When an ambient temperature is less than a first threshold, the heating component pre-heats the at least one battery. In exemplary embodiments, the heating component includes at least one brake resistor that is coupled to the electric power source loop.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. Ser. No. 17/557,396 filed onDec. 21, 2021, now U.S. Patent Application Publication 2022-0194165entitled “Vehicle Thermal Management Systems and Methods.” U.S. Ser. No.17/557,396 claims priority to, and the benefit of, U.S. ProvisionalPatent Application No. 63/195,484 filed on Jun. 1, 2021 entitled“Vehicle Thermal Management Systems and Methods” and to U.S. ProvisionalPatent Application No. 63/129,307 filed on Dec. 22, 2020 entitled“Thermal Management System and Method Using a Common Radiator.” Thedisclosure of the foregoing applications is incorporated herein byreference in its entirety, including but not limited to those portionsthat specifically appear hereinafter, but except for any subject matterdisclaimers or disavowals, and except to the extent that theincorporated material is inconsistent with the express disclosureherein, in which case the language in this disclosure shall control.

TECHNICAL FIELD

The present disclosure relates to thermal management systems, and moreparticularly, to thermal management systems for vehicles with electricpower sources.

BACKGROUND

Alternative fuel vehicles such as battery electric vehicles (BEV) andfuel cell electric vehicles (FCEV) utilize electric drive trains, incontrast to traditional petroleum or diesel-powered drive trains. Forexample, the electricity provided by a battery pack or generated by afuel cell stack may be used to power one or more electric motors todrive the vehicle's wheels and to power multiple other electricallyoperated systems of the vehicle. Traditionally, waste heat from the fuelcell stack and/or battery is captured by a coolant and routed to aradiator, thereby removing the waste heat from the system by releasingit to the ambient environment. Accordingly, approaches which utilizethis waste heat in alternative ways to increase system thermalefficiency and increase vehicle lifespan and performance may bedesirable.

SUMMARY

In an exemplary embodiment, a thermal management system for a vehiclecomprises: an electric power source loop comprising at least onebattery; and a heating component thermally coupled to the electric powersource loop. When an ambient temperature is less than a first threshold,the heating component pre-heats the at least one battery.

In another exemplary embodiment, a method of increasing thermalefficiency in a thermal management system of a vehicle comprises:determining if an ambient temperature of one or more batteries in anelectric source loop is less than a first threshold; and when theambient temperature is less than the first threshold, pre-heating theone or more batteries.

In another exemplary embodiment, a vehicle comprises a brake resistor;and one or more battery packs coupled to the brake resistor. When anambient temperature is less than a first threshold, the brake resistoris configured to pre-heat at least one of the one or more battery packs.

The contents of this section are intended as a simplified introductionto the disclosure and are not intended to limit the scope of any claim.The foregoing features and elements may be combined in variouscombinations without exclusivity, unless expressly indicated otherwise.These features and elements as well as the operation thereof will becomemore apparent in light of the following description and the accompanyingdrawings. It should be understood, however, the following descriptionand drawings are intended to be exemplary in nature and non-limiting.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings are included to provide a furtherunderstanding of the present disclosure and are incorporated in, andconstitute a part of, this specification, illustrate variousembodiments, and together with the description, serve to explainexemplary principles of the disclosure.

FIG. 1 illustrates a block diagram of an example thermal managementsystem in a vehicle, in accordance with various embodiments;

FIG. 2 illustrates a block diagram of an example battery electricvehicle thermal management system, in accordance with variousembodiments;

FIG. 3 illustrates a block diagram of an example fuel cell electricvehicle thermal management system, in accordance with variousembodiments; and

FIG. 4 illustrates a flow diagram of an example method of utilizing acommon radiator for thermal management in a vehicle.

DETAILED DESCRIPTION

The detailed description of various embodiments herein makes referenceto the accompanying drawings, which show various embodiments by way ofillustration. While these various embodiments are described insufficient detail to enable those skilled in the art to practice thedisclosure, it should be understood that other embodiments may berealized and that logical chemical, electrical, and mechanical changesmay be made without departing from the spirit and scope of thedisclosure. Thus, the detailed description herein is presented forpurposes of illustration only and not of limitation.

For example, the steps recited in any of the method or processdescriptions may be executed in any suitable order and are notnecessarily limited to the order presented. Furthermore, any referenceto singular includes plural embodiments, and any reference to more thanone component or step may include a singular embodiment or step. Also,any reference to attached, fixed, connected, or the like may includepermanent, removable, temporary, partial, full, and/or any otherpossible attachment option. Additionally, any reference to withoutcontact (or similar phrases) may also include reduced contact or minimalcontact.

For example, in the context of the present disclosure, methods, systems,and articles may find particular use in connection with electricvehicles, fuel cell electric vehicles, compressed natural gas (CNG)vehicles, hythane (mix of hydrogen and natural gas) vehicles, and/or thelike. However, various aspects of the disclosed embodiments may beadapted for performance in a variety of other systems. Further, in thecontext of the present disclosure, methods, systems, and articles mayfind particular use in any system requiring use of a battery, fuel cell,and/or thermal management system of the same. As such, numerousapplications of the present disclosure may be realized.

Electric vehicles may generate large amounts of waste heat through theoperation of various system components. For example, battery systems maygenerate waste heat as a result of enthalpy changes and resistiveheating inside of battery cells, among other reasons. This additionalheat may negatively affect consistent operation of a battery, which inturn may reduce the operational life of the battery. Further, althoughfuel cells often operate at higher temperatures than battery systems,the heat generated by the fuel cell may negatively impact operation ofother components of the vehicle. By increasing the thermal efficiency ofthe thermal management system, certain components of the thermalmanagement system may require less power from on-board batteries. As aresult, battery capacity may be preserved and instead be utilized forother desirable purposes, for example to increase vehicle range.

FIG. 1 illustrates an exemplary embodiment of a thermal managementsystem 170. In various embodiments, a vehicle 100 comprises and/or isconfigured with thermal management system 170. Vehicle 100 may comprise,for example, a battery electric vehicle. In various embodiments, vehicle100 is a fuel cell electric vehicle. Thermal management system 170 mayinclude a brake resistor loop 112, an electric power source loop 102,and at least one common radiator 120.

Brake resistor loop 112 may comprise at least one brake resistor 118. Invarious embodiments, brake resistor loop 112 may comprise multiple brakeresistors 118. In further embodiments, multiple brake resistors 118 arecoupled in a parallel configuration. In various embodiments, brakeresistor(s) 118 are required to operate when one or more batteriescomprised in electric power source 108 is fully charged. For example,when vehicle 100 is decelerating, regenerative braking may be used. Oneor more batteries of vehicle 100 are charged using regenerative brakingpower. When one or more batteries are fully charged, but vehicle 100 isstill decelerating, regenerative braking may no longer be used and brakeresistor(s) 118 may be used instead for braking.

Brake resistor loop 112 may further comprise a brake resistor controller116 that is configured to control operation of brake resistor 118. Invarious embodiments, brake resistor 118 comprises a built-in brakeresistor controller 116. In other embodiments, brake resistor controller116 is external to brake resistor 118. In further embodiments, brakeresistor controller 116 and brake resistor 118 are thermally coupled toeach other in a parallel configuration.

During certain events, such as deceleration of vehicle 100, brakeresistor loop 112 may utilize and/or absorb significant amounts ofelectrical energy, which is at least partially converted into heat.Further, in various embodiments, vehicle 100 may need to deceleratewhile driving down a slope, increasing the heat generated in brakeresistor loop 112. In order to maintain a temperature of brake resistorloop 112 within a desired range, heat is dissipated by circulating acoolant through brake resistor loop 112 and common radiator 120. Invarious embodiments, common radiator 120 may comprise a fan configuredto assist in convective heat transfer to an external environment. Theflow of the coolant circulating through brake resistor loop 112 may befurther enhanced by pump 114, which may be thermally coupled in serieswith brake resistor controller 116 and brake resistor 118. In suchembodiments, when brake resistor loop 112 is in operation, the coolantflows through brake resistor loop 112 and common radiator 120.

As discussed herein, two components may be considered “thermallycoupled” when thermal energy from one or both components may betransferred into a common cooling fluid, or vice versa. For example, acoolant pumped by pump 114 may be split to circulate through both brakeresistor controller 116 and brake resistor 118 before the coolantcombines to flow through outlets 152 and 156. Thus, thermal energy fromboth brake resistor controller 116 and brake resistor 118 is nowtransferred into this coolant and brake resistor controller 116 andbrake resistor 118 may be considered “thermally coupled.” Further, thecoolant from brake resistor loop 112 may then circulate through commonradiator 120 via outlets 152 and 156. Thus, because brake resistor loop112 and common radiator 120 are connected via a coolant loop path, theymay be considered “thermally coupled.”

In various embodiments, electric power source loop 102 is also thermallycoupled to common radiator 120. Electric power source loop 102 comprisesat least one electric power source 108 and at least one pump 104. Invarious embodiments, electric power source 108 comprises one or morefuel cells. Electric power source 108 may comprise one or more batterysystems, including in combination with one or more fuel cells. Invarious embodiments, electric power source loop 102 is further thermallycoupled to an alternate cooling system 130. Alternate cooling system 130may comprise, for example a second radiator 138, a refrigeration system136, or any other suitable cooling system.

In various embodiments, when electric power source loop 102 is inoperation, and when brake resistor loop 112 is not in operation, tomaintain the temperature of the electric power source 108 in a desiredtemperature range, heat generated in electric power source 108 may bedissipated by circulating a coolant through the electric power sourceloop 102 and common radiator 120. When electric power source loop 102 isin operation, and when brake resistor loop 112 is also in operation,heat generated in electric power source 108 may be dissipated bycirculating the coolant through electric power source loop 102 andalternate cooling system 130.

In various embodiments, common radiator 120 is thermally coupled to afirst valve 132 and a second valve 134. First valve 132 may be a 3-wayvalve or a 4-way valve, for example. In various examples, second valve134 may be a 3-way valve. In various embodiments, first valve 132 isfurther thermally coupled to brake resistor loop 112, and brake resistorloop 112 is further thermally coupled to second valve 134. Similarly,first valve 132 and second valve 134 may be thermally coupled toelectric power source loop 102. First valve 132 and second valve 134 mayassist in preventing the coolant from brake resistor loop 112 fromflowing through electric power source loop 102, and in preventing thecoolant from electric power source loop 102 from flowing through brakeresistor loop 112.

In various embodiments, when brake resistor 118 is in operation andelectric power source 108 is not in operation, thermal management system170 is in brake resistor mode. When thermal management system 170 is inbrake resistor mode, second valve 134 is configured to open outlets 152(facing brake resistor loop 112) and 156 and close outlet 154 (facingelectric power source loop 102). In such embodiments, first valve 132 isconfigured to close at least outlet 142. Accordingly, the coolantcirculating through brake resistor loop 112 does not flow throughelectric power source loop 102 in these configurations.

In various embodiments, when electric power source 108 is in operationand brake resistor loop 112 is not in operation, thermal managementsystem 170 is in electric power source mode. When thermal managementsystem 170 is in electric power source mode, second valve 134 isconfigured to open outlets 154 and 156 and close outlet 152. In suchembodiments, first valve 132 is configured to open outlets 142 (facingcommon radiator 120) and 144 (facing electric power source loop 108) andclose outlet 146 (facing alternate cooling system 130). Accordingly, thecoolant circulating through electric power source loop 102 does not flowthrough brake resistor loop 112 or through alternate cooling system 130in these configurations.

In various embodiments, when electric power source 108 and brakeresistor 118 are in operation, thermal management system 170 is inalternate cooling mode. When thermal management system 170 is inalternate cooling mode, second valve 134 is configured to open outlets152 and 156 but keep outlet 154 closed, and first valve 132 isconfigured to open outlets 146 and 144 but keep outlet 142 closed. Thus,the coolant circulating through the brake resistor loop 112 flowsthrough common radiator 120, but the coolant circulating throughelectric power source loop 102 does not flow through common radiator 120or brake resistor loop 112. Instead, the coolant from electric powersource loop 102 circulates through alternate cooling system 130 andelectric power source loop 102 to dissipate heat generated by operationof electric power source 108.

In various embodiments, first valve 132 is a 4-way valve. Valve 132 maybe thermally coupled to heating sub-system 160 at outlet 148. In variousembodiments, when the ambient temperature is less than a firsttemperature threshold, thermal management system 170 operates in aheater mode. In the heater mode, first valve 132 is configured to openoutlets 148 and 144, and further configured to close outlets 142 and 146such that the coolant flowing through electric power source loop 102 iscirculated through heating sub-system 160 to pre-heat one or morebatteries comprised in electric power source loop 102 but prevents thecoolant from flowing through brake resistor loop 112. In suchembodiments, second valve 134 is configured to close outlets 152, 154,and 156 to prevent the coolant flowing from electric power source loop108 from flowing through common radiator 120. In various embodiments,valve 134 has a shut-off function.

In various exemplary embodiments, the first temperature threshold iswithin a range of about 0 degrees Celsius to 20 degrees Celsius. Infurther exemplary embodiments, the first temperature threshold is withina range of 0 degrees to 15 degrees Celsius. In some exemplaryembodiments, the first temperature threshold is 0 degrees Celsius orless. In various embodiments, one or more batteries comprised inelectric power source loop 102 are pre-heated when vehicle 100 isstarted. For example, one or more batteries may be heated prior tooperation of electric power source 108.

In various embodiments, heating sub-system 160 comprises a shut-offvalve 164. Shut-off valve 164 is thermally coupled to electric powersource loop 102 and to brake resistor loop 112. In various embodiments,when the ambient temperature is less than a first temperature threshold,shut-off valve 164 and brake resistor loop 112 may be used to pre-heatone or more batteries comprised in electric power source loop 102. Whenbrake resistor 118 is operating, heat is generated in brake resistorloop 112. When an ambient temperature is less than a first temperaturethreshold, this heat generated in brake resistor loop 112 may beutilized to pre-heat one or more batteries comprised in electric powersource loop 102.

For example, in the heating mode, shut-off valve 164 may be opened toallow the coolant flowing from electric power source loop 102 to becirculated through at least a part of the brake resistor loop 112.Because all outlets of valve 134 are closed, the coolant flowing fromelectric power source loop 102 does not circulate through commonradiator 120. Further, brake resistor loop 112 may be thermally coupledto valve 132 at outlet 148. Outlets 148 and 144 of valve 132 areconfigured to be open in the heating mode and the heated coolant flowingfrom brake resistor loop 112 may then be circulated through electricpower source loop 102 via valve 132 to pre-heat one or more batteriescomprised in electric power source loop 102. Again, because all outletsof valve 134 are closed, the heated coolant flowing from brake resistorloop 112 does not circulate through common radiator 120.

In various embodiments, heating sub-system 160 comprises an auxiliaryheater 162. Heater 162 may be thermally coupled to valve 132 at outlet148 and may further be used to pre-heat one or more batteries comprisedin electric power source loop 102. For example, the coolant flowing fromelectric power source loop 102 may be circulated through heater 162.This heated coolant may then be circulated back to electric power sourceloop 102 via valve 132 to pre-heat one or more batteries comprised inelectric power source loop 102.

In various embodiments, when heater 162 is used to pre-heat one or morebatteries comprised in electric power source loop 102, shut-off valve164 is closed such that the coolant from electric power source loop 102does not circulate through brake resistor loop 112. In variousembodiments, both heater 162 and brake resistor 118 may be utilized topre-heat one or more batteries comprised in electric power source loop102.

As discussed herein, an “outlet” may be any orifice or cavity thatenables fluid connection between two components. For example, coolantflowing from brake resistor loop 112 flows into outlet 152 and flows outof outlet 156 to circulate through common radiator 120. Thus, 152 and156 are both considered “outlets” because they enable fluid connectionbetween brake resistor loop 112 and common radiator 120.

With reference now to FIG. 2, a thermal management system 200 for abattery electric vehicle (BEV) in accordance with the present disclosureis illustrated. In various embodiments, thermal management system 200includes a brake resistor (BR) pump 214 thermally coupled to brakeresistor (BR) controller 216 and at least one brake resistor (BR) 218.BR controller 216 and BR 218 may be thermally coupled in parallel witheach other. Accordingly, in various embodiments, when BR 218 is inoperation, to dissipate heat generated in BR 218, a coolant from brakeresistor (BR) expansion tank 212 is pumped by BR pump 214 and circulatedthrough BR controller 216 and BR 218. In various embodiments, BR 218 maybe in operation when a vehicle comprising thermal management system 200is driving down a slope. Thermal management system 200 may furthercomprise, for example, a first valve 222 having outlets 222-1 (facing BR218), 222-2 (facing battery loop 250) and 222-3 (facing common radiator220). In such configurations, when BR 218 is in operation, first valve222 is configured to open outlets 222-1 and 222-3, which allows coolantcirculating through the brake resistor loop 280 to flow through commonradiator 220 and blocks any other coolant from flowing through commonradiator 220. Accordingly, common radiator 220 is operable to cool BRcontroller 216 and/or BR 218 (but not other components of vehicle 100)when BR 218 is in operation.

Thermal management system 200 may further comprise, for example, abattery loop 250 comprising one or more batteries 208 thermally coupledto common radiator 220. One or more batteries 208 may also be thermallycoupled to a refrigeration system 230. In various embodiments, thermalmanagement system 200 includes a second valve 224, which may be a 3-wayor a 4-way valve. Second valve 224 may be thermally coupled to batteryloop 250 at outlet 224-3, thermally coupled to common radiator 220 atoutlet 224-1, and thermally coupled to refrigeration system 230 atoutlet 224-4.

When BR 218 is not in operation, common radiator 220 may be used bybattery loop 250 to dissipate heat generated in one or more batteries208. In various embodiments, when the ambient temperature is greaterthan a second temperature threshold, one or more batteries 208 mayutilize common radiator 220 to dissipate heat generated by one or morebatteries 208. For example, the second temperature threshold may be in arange of about 20 degrees Celsius to 40 degrees Celsius. In furtherexamples, the second temperature threshold may be in a range of about 25degrees Celsius to 35 degrees Celsius. In even further examples, thesecond temperature threshold may be 30 degrees Celsius. Battery loop 250may, for example, be coupled to at least one pump 204. In variousembodiments, all batteries in battery loop 250 are coupled to a singlepump 204. In other embodiments, one or more batteries 208 (such asbatteries 208 a, 208 b and 208 c) are thermally coupled to a separatepump, such as pumps 204 a, 204 b and 204 c, respectively.

When BR 218 is not in operation and when one or more batteries 208 areoperating, to dissipate heat generated in batteries 208 a coolant frombattery expansion tank 202 may be pumped by one or more battery pump(s)204 and circulated through batteries 208. In various embodiments, whenBR 218 is not operating and when one or more batteries 208 areoperating, first valve 222 is configured to open outlets 222-2 and 222-3to allow coolant circulating through battery loop 250 to flow throughcommon radiator 220. First valve 222 may be configured to close outlet222-1 so that common radiator 220 is not utilized by BR 218 while it isbeing utilized by battery loop 250. Further, second valve 224 may beconfigured to open at outlets 224-1 and 224-3 so that the coolant canflow through common radiator 220 and battery loop 250 to dissipate heatgenerated in one or more batteries 208. In various embodiments, whenbattery loop 250 is utilizing common radiator 220, refrigeration system230 may not be utilized for dissipating heat generated in one or morebatteries 208. Accordingly, second valve 224 may be configured to closeoutlet 224-2 coupled to refrigeration system 230.

When BR 218 is in operation and when one or more batteries 208 are inoperation, common radiator 220 may be utilized by BR 218 and BRcontroller 216 to dissipate heat generated by BR 218. In variousembodiments, both BR 218 and one or more batteries 208 may be inoperation when vehicle 100 is driving down a slope. First valve 222 maybe configured to open outlets 222-1 and 222-3 to allow coolantcirculating through brake resistor loop 280 to flow through commonradiator 220, and further configured to close outlet 222-2 to stopcoolant circulating through battery loop 250 from flowing through commonradiator 220.

In various embodiments, when the ambient temperature is greater than thesecond temperature threshold one or more batteries 208 may also requirecooling. For example, the second temperature threshold may be within arange of 25 degrees Celsius and 35 degrees Celsius. In a furtherexample, the second temperature threshold is 30 degrees Celsius. Becausethe common radiator 220 is utilized by BR loop 212 for cooling, batteryloop 250 may utilize refrigeration system 230 to dissipate heatgenerated by one or more batteries 208. Accordingly, second valve 224may be configured to open outlets 224-4 and 224-3 to allow coolantcirculating through battery loop 250 to flow through refrigerationsystem 230, and further configured to close outlet 224-1 to stop coolantflowing out of common radiator 220 from flowing through battery loop250. Thus, when common radiator 220 is used by BR 218, heat generated inbatteries 208 may be dissipated using refrigeration system 230.

In various embodiments, second valve 224 is a 4-way valve. Valve 224may, for example, be thermally coupled to a heater 226 at outlet 224-2.In various embodiments, when the ambient temperature is less than afirst temperature threshold, second valve 224 is configured to openoutlet 224-2 and outlet 224-4, and configured to close outlets 224-1 and224-3 such that coolant flowing through battery loop 250 is circulatedthrough heater 226 to pre-heat one or more batteries 208. For example,the first temperature threshold may be in an approximate range of 0degrees Celsius to 20 degrees Celsius. In further examples, batteries208 may be pre-heated when the ambient temperature is less than 0degrees Celsius. In such embodiments, first valve 222 may be configuredto close at least outlet 222-2 to prevent coolant flowing throughbattery loop 250 from flowing through common radiator 220. In variousembodiments, one or more batteries 208 are pre-heated when vehicle 100is started. For example, one or more batteries may be pre-heated priorto operation of brake resistor 218 or one or more batteries 208.

Battery loop 250 may comprise, for example, three batteries 208 a, 208b, and 208 c. However, battery loop 250 may comprise any suitable numberof batteries 208, such as two batteries 208, four batteries 208, sixbatteries 208, nine batteries 208, and/or the like. Batteries 208 a, 208b, and 208 c are further coupled to pumps 204 a, 204 b, and 204 c,respectively, via shut off valves 206 a, 206 b, and 206 c, respectively.In various embodiments, based on operational needs of vehicle 100, onlysome of the batteries 208 may be in operation. For example, battery 208a and battery 208 b may be configured to operate while battery 208 c maybe configured to disconnect. In such embodiments, shut-off valve 206 cmay be configured to close its respective outlets such that the coolantcirculating through battery loop 250 does not flow through battery 208c, causing the coolant circulating through battery loop 250 to insteadflow only through batteries 208 a and 208 b. Similarly, if battery 208 aand/or battery 208 b are disconnected, shut-off valves 206 a and/or 206b may similarly be configured to close their corresponding outlets andrestrict the coolant from flowing through the disconnected batteries.

Further, battery loop 250 may include at least one check valve 210configured to maintain the circulation of the coolant flowing out ofbattery loop 250 and direct it through one of common radiator 220 orrefrigeration system 230 such that it may thereafter circulate backthrough battery loop 250. In exemplary embodiments, each battery 208(such as 208 a, 208 b, and 208 c) is coupled to an individual checkvalve 210 (such as 210 a, 210 b, and 210 c, respectively).

In various embodiments, cooling objectives for one or more batteries 208and brake resistor(s) 218 may be different. For example, one or morebatteries 208 may be desired to maintain a temperature within a range ofabout 25° Celsius and about 40° Celsius for efficient operation, andbrake resistor(s) 218 may be desired to maintain a temperature within arange of about 75° Celsius and about 95° Celsius for efficientoperation.

With reference now to FIG. 3, a thermal management system 300 for a fuelcell electric vehicle (FCEV) in accordance with the present disclosureis illustrated. In various embodiments, thermal management system 300includes a brake resistor (BR) loop 380 that may further comprise abrake resistor (BR) pump 314 thermally coupled to brake resistor (BR)controller 316 and at least one brake resistor (BR) 318. BR controller316 and BR 318 may, for example, be thermally coupled to each other in aparallel configuration. Thermal management system 300 may furthercomprise at least one fuel cell loop 350. In various embodiments, fuelcell loop 350 comprises one or more fuel cells 308 (such as 308 a and308 b) thermally coupled to pump 304. For example, each of fuel cells308 may be thermally coupled to a single pump 304, or each individualfuel cell 308 a and 308 b may be coupled to a separate pump 304 a and304 b, respectively. Shut off valves 306 a, 306 b may be disposedbetween respective pumps 304 a, 304 b and fuel cells 308 a, 308 b, andcheck valves 310 a, 310 b may be disposed on the other side of fuelcells 308 a, 308 b respectively.

Thermal management system 300 may further include at least two radiators320 a and 320 b, each of which may be thermally coupled to fuel cellloop 350. Further, at least one of the two radiators 320 may also bethermally coupled to BR loop 380. In various embodiments, thermalmanagement system 300 further includes a first 3-way valve 322 coupledto BR loop 380 at outlet 322-1, coupled to fuel cell loop 350 at outlet322-2, and coupled to first radiator 320 a at outlet 322-3. Further,thermal management system 300 may include a second 3-way valve 324coupled to first radiator 320 a at outlet 324-1, coupled to secondradiator 320 b at outlet 324-2, and coupled to fuel cell loop 350 atoutlet 324-3.

When one or more fuel cells 308 are in operation, to dissipate heatgenerated by fuel cell 308, first radiator 320 a and/or second radiator320 b may be utilized by fuel cell loop 350. In various embodiments,coolant from fuel cell (FC) expansion tank 302 is pumped by at least oneFC pump 304 and circulated through one or more fuel cells 308. Invarious embodiments, both radiators 320 a and 320 b may be utilized byfuel cell loop 350 to dissipate heat generated by one or more fuel cells308. In such embodiments, first valve 322 is configured to open outlets322-2 and 322-3 to allow coolant circulating through FC loop 350 to flowthrough first radiator 320 a. First valve 322 may be configured to closeoutlet 322-1 coupled with BR loop 380, preventing coolant from flowingto or from BR loop 380. Further, second valve 324 may be configured toopen all three outlets 324-1, 324-2, and 324-3. In such embodiments,coolant flowing through first radiator 320 a may flow back through FCloop 350 via outlets 324-1 and 324-3. Further, the coolant may also flowthrough second radiator 320 b. The coolant flowing through secondradiator 320 b may flow back through FC loop 350 via outlets 324-2 and324-3.

In various embodiments, when one or more fuel cells 308 are inoperation, a single radiator may be utilized to dissipate heat generatedby one or more fuel cells 308. In such embodiments, after the coolanthas circulated through one or more fuel cells 308, the coolant flowsthrough either first radiator 320 a or second radiator 320 b.Accordingly, first valve 322 may be configured to open outlet 322-2 and322-3 and close outlet 322-1, and second valve 324 may be configured toopen outlet 324-1 and 324-3 and close outlet 324-2. Thus, the coolantmay only be circulated through first radiator 320 a (and not throughsecond radiator 320 b). Alternatively, in various embodiments, thecoolant from fuel cells 308 may not circulate via first valve 322. Forexample, first valve 322 may be configured to close its outlets 322-1,322-2, and 322-3, and second valve 324 is configured to open outlets324-2 and 324-3 and close outlet 324-1. Thus, the coolant is circulatedonly through second radiator 320 b (and not through first radiator 320a).

When BR 318 is in operation, to dissipate heat generated in BR 318, acoolant may be pumped by BR pump 314 and circulated through BR loop 380.In exemplary embodiments, the coolant is pumped by BR pump 314 from BRexpansion tank 312. In various embodiments, BR 318 may be in operationwhen vehicle 100 is driving down a slope, and the coolant from the BRloop 380 may be circulated through at least one radiator 320. Firstvalve 322 may, for example, be configured to open outlet 322-1 and 322-3and close outlet 322-2, allowing coolant flowing from BR loop 380 andcirculate through first radiator 320 a while preventing other coolantfrom flowing through first radiator 320 a. Further, second valve 324 isconfigured to close outlet 324-1, allowing coolant flowing through firstradiator 320 a to circulate back through BR loop 380 (and not circulatethrough FC loop 350).

When, along with BR 318, one or more fuel cells 308 are also inoperation, second radiator 320 b may be utilized by FC loop 350 todissipate heat generated in one or more fuel cells 308. In suchembodiments, second valve 324 is configured to open outlet 324-2 and324-3 to allow the coolant circulating from the FC loop 350 to flowthrough second radiator 320 b and back through FC loop 350. Becauseoutlets 322-2 and 324-1 are closed, the coolant flowing through FC loop350 does not circulate through first radiator 320 a and the coolantflowing through BR loop 380 does not flow in FC loop 350. Thus, based onoperational needs of vehicle 100, first radiator 320 a may be utilizedby either BR loop 380 or FC loop 350.

With reference now to FIG. 4, a method 400 of utilizing a commonradiator for thermal management in a vehicle in accordance with thepresent disclosure is illustrated. Method 400 may be implemented byvehicle thermal management systems described herein. A first step ofmethod 400 comprises determining if a brake resistor within a vehicle,such as one comprising thermal management system 170, is in operation(step 406). When a vehicle is in operation, method 400 may furthercomprise a step of using a common radiator to cool the brake resistor,such as brake resistor 118 (step 410). When the brake resistor is not inoperation, method 400 may further comprise a step of using a commonradiator to cool an electric power source, such as power source 108(step 408). In various embodiments, the electric power source comprisesone or more batteries. In various embodiments, the electric power sourcecomprises at least one fuel cell.

In various embodiments of method 400, prior to determining if the brakeresistor is in operation, method 400 may further comprise a step ofdetermining if an ambient temperature is less than a first temperaturethreshold (step 402). In various embodiments, the first temperaturethreshold may be in a range of 0 degrees Celsius and 15 degrees Celsius.In various embodiments, the first temperature threshold may be 0 degreesCelsius. When the ambient temperature is less than a first temperaturethreshold, method 400 may further comprise a step of pre-heating atleast one battery comprised in the electric power source (step 404). Forexample, when the vehicle is started, the ambient temperature may beless than a first temperature threshold. In such an event, a heatingcomponent may be used to pre-heat at least one battery comprised in theelectric power source prior to operation of the brake resistor. Invarious embodiments, the heating component may be a heater. In variousembodiments, the heating component may be the brake resistor. Theheating component as described herein is a device that generates heatabsorbed by coolant flowing from an electric power source loop, such aselectric power source loop 102.

In various embodiments, responsive to a determination that the brakeresistor is in operation, method 400 further comprises determining ifthe electric power source is in operation. When the electric powersource is in operation, method 400 comprises utilizing an alternatecooling system to cool the electric power source (step 412). In variousembodiments, the step of utilizing a common radiator to cool an electricpower source further comprises determining if the electric power sourceis in operation.

In various embodiments, wherein the electric power source comprises oneor more batteries, method 400 further comprises a step of determining ifan ambient temperature is greater than a second temperature threshold.When the ambient temperature is greater than a second temperaturethreshold, method 400 comprises a step of utilizing a refrigerationsystem to cool the one or more batteries. The second temperaturethreshold may be between 25 degrees Celsius and 35 degrees Celsius.

Principles of the present disclosure may be compatible and/or utilizedin connection with principles set forth in U.S. Ser. No. 17/403,179filed Aug. 16, 2021, now U.S. Pat. No. 11,279,243 entitled “High VoltageElectrical System for Battery Electric Vehicle” and/or with principlesset forth in with U.S. Ser. No. 17/321,724 filed May 17, 2021, now U.S.Pat. No. 11,124,076 entitled “Electric Vehicle Battery Frame Assembly.”The contents of the foregoing applications are incorporated herein byreference, but except for any subject matter disclaimers or disavowals,and except to the extent that the incorporated material is inconsistentwith the express disclosure herein, in which case the language in thisdisclosure shall control.

Example Embodiments

Example 1 includes a thermal management system for a vehicle,comprising: a common radiator; a brake resistor loop comprising at leastone brake resistor and a brake resistor controller thermally coupled tothe common radiator; and an electric power source loop comprising atleast one electric power source thermally coupled to the commonradiator, wherein when the brake resistor loop is determined to be inoperation, the common radiator absorbs heat generated by the brakeresistor loop.

Example 2 includes the thermal management system of Example 1, furthercomprising: an alternate cooling system thermally coupled to theelectric power source loop, wherein when the brake resistor loop and theelectric power source are determined to be in operation at the sametime, the alternate cooling system absorbs heat generated by theelectric power source loop.

Example 3 includes the thermal management system of any of Examples 1-2,wherein the electric power source loop further comprises at least onebattery.

Example 4 includes the thermal management system of any of Examples 2-3,wherein the alternate cooling system comprises a refrigeration system.

Example 5 includes the thermal management system of any of Examples 3-4,wherein the electric power source loop comprises three batteries, andwherein each battery is thermally coupled in parallel with the otherbatteries.

Example 6 includes the thermal management system of any of Examples 1-5,wherein the electric power source loop further comprises at least onefuel cell.

Example 7 includes the thermal management system of Example 6, whereinthe electric power source loop comprises two fuel cells, and wherein thetwo fuel cells are thermally coupled in parallel with one another.

Example 8 includes the thermal management system of any of Examples 1-7,further comprising a second radiator, wherein the second radiator isthermally coupled to the brake resistor loop and thermally coupled tothe electric power source loop.

Example 9 includes the thermal management system of any of Examples 2-8,wherein the alternate cooling system comprises a second radiator.

Example 10 includes the thermal management system of any of Examples3-9, wherein when ambient temperature is less than a first temperaturethreshold, heat generated by the brake resistor loop pre-heats the atleast one battery.

Example 11 includes the thermal management system of any of Examples3-10, wherein when ambient temperature is less than a first temperaturethreshold, heat generated by a heater pre-heats the at least onebattery.

Example 12 includes a method of increasing thermal efficiency in athermal management system of a vehicle, the method comprising:determining if a brake resistor comprised within the vehicle is inoperation, wherein the vehicle further comprises a common radiator andan electric power source; when the brake resistor is in operation,utilizing the common radiator to cool the brake resistor; and when thebrake resistor is not in operation, utilizing the common radiator tocool the electric power source.

Example 13 includes the method of Example 12, wherein prior todetermining if the brake resistor in operation, the method furthercomprises: determining if an ambient temperature is less than a firsttemperature threshold; and when the ambient temperature is less than thefirst temperature threshold, utilizing a heater to pre-heat the electricpower source.

Example 14 includes the method of any of Examples 12-13, wherein thefirst temperature threshold is between 0 degrees Celsius and 15 degreesCelsius.

Example 15 includes the method of any of Examples 12-14, wherein priorto determining if the brake resistor is in operation, the method furthercomprises: determining if an ambient temperature is less than a firsttemperature threshold; and when the ambient temperature is less than thefirst temperature threshold, pre-heating at least one battery comprisedin the electric power source.

Example 16 includes the method of Example 15, wherein pre-heating atleast one battery comprised in the electric power source furthercomprises utilizing a heater to pre-heat the at least one battery.

Example 17 includes the method of any of Examples 15-16, wherein whenthe brake resistor is in operation, pre-heating at least one batterycomprised in the electric power source further comprises utilizing abrake resistor to pre-heat the at least one battery.

Example 18 includes the method of Example 17, wherein utilizing a brakeresistor to pre-heat the at least one battery further comprises:circulating a coolant flowing from the electric power source through thebrake resistor to; and circulating the heated coolant back through theelectric power source.

Example 19 includes the method of any of Examples 12-17, whereinresponsive to a determination that the brake resistor is in operation,the method further comprises: determining if the electric power sourceis in operation; and when the electric power source is in operation,utilizing an alternate cooling system to cool the electric power source.

Example 20 includes the method of any of Examples 12-19, wherein theelectric power source comprises one or more batteries.

Example 21 includes the method of Example 20, wherein responsive to adetermination that the brake resistor is in operation, the methodfurther comprises: determining if an ambient temperature is greater thana second temperature threshold; when the ambient temperature is greaterthan a second temperature threshold, utilizing a refrigeration system tocool the one or more batteries.

Example 22 includes the method of Example 21, wherein the secondtemperature threshold is between 25 degrees Celsius and 35 degreesCelsius.

Example 23 includes a thermal management system for a vehicle,comprising: one or more radiators; a brake resistor thermally coupled toat least one of the one or more radiators; one or more fuel cellsthermally coupled to at least one of the one or more radiators; whereinwhen the brake resistor is determined to be in operation, the at leastone radiator absorbs heat generated by the brake resistor; and whereinwhen the brake resistor is determined not to be in operation, the atleast one radiator absorbs heat generated by the one or more fuel cells.

Example 24 includes the thermal management system of Example 23, furthercomprising: at least one 3-way valve, wherein the brake resistor iscoupled to the 3-way valve, wherein the one or more fuel cells arecoupled to the 3-way valve, and wherein at least one of the one or moreradiators is coupled to a 3-way valve; and wherein when the brakeresistor is determined to be in operation, the 3-way valve thermallycouples the at least one radiator with the brake resistor; and whereinwhen the brake resistor is determined not to be in operation, the 3-wayvalve thermally couples the at least one radiator to the one or morefuel cells.

Example 25 includes the thermal management system of any of Examples23-24, wherein the at least one radiator comprises a first radiator anda second radiator.

Example 26 includes the thermal management system of Example 25, whereinthe first radiator is thermally coupled to the brake resistor, whereinthe first radiator is thermally coupled to the one or more fuel cells,wherein the second radiator is thermally coupled to the one or more fuelcells, and wherein when the brake resistor is determined to be inoperation, the first radiator absorbs heat generated by the brakeresistor, and the second radiator absorbs heat generated by the one ormore fuel cells.

Example 27 includes the thermal management system of Example 26, furthercomprising: a first 3-way valve, wherein the brake resistor is coupledto the first 3-way valve, wherein the one or more fuel cells are coupledto the first 3-way valve, and wherein the first radiator is coupled tothe first 3-way valve; and wherein when the brake resistor is determinedto be in operation, the first 3-way valve thermally couples the firstradiator with the brake resistor; and wherein when the brake resistor isdetermined not to be in operation, the first 3-way valve thermallycouples the first radiator to the one or more fuel cells.

Example 28 includes the thermal management system of Example 27, furthercomprising: a second 3-way valve, wherein the first radiator is coupledto the second 3-way valve, wherein the one or more fuel cells arecoupled to the second 3-way valve, and wherein the second radiator iscoupled to the second 3-way valve.

Example 29 includes the thermal management system of Example 28, whereinwhen the brake resistor is determined to be in operation, the second3-way valve thermally couples the second radiator to the one or morefuel cells such that the second radiator absorbs heat generated by theone or more fuel cells.

Example 30 includes the thermal management system of Example 29, whereinwhen the brake resistor is determined to not be in operation, the first3-way valve thermally couples the first radiator to the one or more fuelcells, wherein the second 3-way valve thermally couples the firstradiator to the one or more fuel cells, and wherein the first radiatorand the second radiator absorb heat generated by the one or more fuelcells.

Example 31 includes the thermal management system of any of Examples23-30, wherein the one or more fuel cells comprise at least two fuelcells.

Example 32 includes the thermal management system of Example 31, whereinthe at least two fuel cells are thermally coupled in parallel to oneanother.

Example 33 includes a thermal management system for a vehicle,comprising: a common radiator; at least one brake resistor coupled tothe common radiator; and one or more batteries coupled to the commonradiator, wherein when the brake resistor is determined to be inoperation, the common radiator absorbs heat generated by the brakeresistor, and wherein when the brake resistor is determined to not be inoperation, the common radiator absorbs heat generated by the one or morebatteries.

Example 34 includes the thermal management system of Example 33, furthercomprising: a refrigeration system coupled to the one or more batteries,wherein when the brake resistor is determined to be in operation, therefrigeration system absorbs heat generated by the one or morebatteries.

Example 35 the thermal management system of any of Examples 33-34,further comprising: a first 3-way valve, wherein the brake resistor iscoupled to the first 3-way valve, wherein the one or more batteries arecoupled to the first 3-way valve, and wherein the common radiator iscoupled to the first 3-way valve, wherein when the brake resistor isdetermined to be in operation, the first 3-way valve thermally couplesthe first radiator with the brake resistor, and wherein when the brakeresistor is determined not to be in operation, the first 3-way valvethermally couples the first radiator to the one or more batteries.

Example 36 includes the thermal management system of Example 35, furthercomprising: a refrigeration system coupled to the one or more batteries;and a second valve, wherein the first radiator is coupled to the secondvalve, wherein the one or more batteries are coupled to the secondvalve, wherein the refrigeration system is coupled to the second valve,wherein when the brake resistor is determined to be in operation, thesecond valve thermally couples the refrigeration system with the one ormore batteries and the refrigeration system absorbs heat generated bythe one or more batteries.

Example 37 includes the thermal management system of any of Examples35-36, wherein the second valve is a 4-way valve, and wherein the secondvalve is further coupled to an auxiliary heater.

Example 38 includes the thermal management system of claim 34, furthercomprising: a shut-off valve, wherein the one or more batteries arecoupled to the shut-off valve, and wherein the brake resistor is coupledto the shut-off valve; wherein the second valve is a 4-way valve, andwherein the brake resistor is coupled to the second valve, and whereinthe one or more batteries are coupled to the second valve; and whereinwhen ambient temperature is determined to be less than a firsttemperature threshold, the shut-off valve thermally couples the one ormore batteries to the brake resistor, and the 4-way valve thermallycouples the brake resistor to one or more batteries.

Example 39 includes a thermal management system for a vehicle,comprising: an electric power source loop comprising at least onebattery; a heating component thermally coupled to the electric powersource loop; wherein when ambient temperature is less than a firsttemperature threshold, the heating component pre-heats the at least onebattery.

Example 40 includes the thermal management system of Example 39, whereinthe heating component comprises at least one brake resistor.

Example 41 includes the thermal management system of Example 40, furthercomprising: a common radiator thermally coupled to the electric powersource loop; and a brake resistor loop comprising the at least one brakeresistor and a brake resistor controller thermally coupled to the commonradiator; wherein when the ambient temperature is greater than the firsttemperature threshold and wherein when the brake resistor loop isdetermined to be in operation, the common radiator absorbs heatgenerated by the brake resistor loop.

Example 42 includes the thermal management system of Example 41, furthercomprising: an alternate cooling system thermally coupled to theelectric power source loop, wherein when the brake resistor loop and theelectric power source are determined to be in operation at the sametime, the alternate cooling system absorbs heat generated by theelectric power source loop.

Example 43 includes the thermal management system of Example 42, whereinthe alternate cooling system comprises a refrigeration system.

Example 44 includes the thermal management system of any of Examples39-43, wherein the electric power source loop comprises three batteries,and wherein each battery is thermally coupled in parallel with the otherbatteries.

Example 45 includes the thermal management system of any of Examples39-44, wherein the electric power source loop further comprises at leastone fuel cell.

Example 46 includes the thermal management system of Example 42, whereinthe alternate cooling system comprises a second radiator.

Benefits, other advantages, and solutions to problems have beendescribed herein with regard to specific embodiments. Furthermore, theconnecting lines shown in the various figures contained herein areintended to represent exemplary functional relationships and/or physicalcouplings between the various elements. It should be noted that manyalternative or additional functional relationships or physicalconnections may be present in a practical system. However, the benefits,advantages, solutions to problems, and any elements that may cause anybenefit, advantage, or solution to occur or become more pronounced arenot to be construed as critical, required, or essential features orelements of the disclosure. The scope of the disclosure is accordinglyto be limited by nothing other than the appended claims, in whichreference to an element in the singular is not intended to mean “one andonly one” unless explicitly so stated, but rather “one or more.”Moreover, where a phrase similar to “at least one of A, B, or C” or “atleast one of A, B, and C” is used in the claims or specification, it isintended that the phrase be interpreted to mean that A alone may bepresent in an embodiment, B alone may be present in an embodiment, Calone may be present in an embodiment, or that any combination of theelements A, B and C may be present in a single embodiment; for example,A and B, A and C, B and C, or A and B and C. Different cross-hatchingmay be used throughout the figures to denote different parts but notnecessarily to denote the same or different materials.

Methods, systems, and articles are provided herein. In the detaileddescription herein, references to “one embodiment”, “an embodiment”,“various embodiments”, etc., indicate that the embodiment described mayinclude a particular feature, structure, or characteristic, but everyembodiment may not necessarily include the particular feature,structure, or characteristic. Moreover, such phrases are not necessarilyreferring to the same embodiment. Further, when a particular feature,structure, or characteristic is described in connection with anembodiment, it is submitted that it is within the knowledge of oneskilled in the art to affect such feature, structure, or characteristicin connection with other embodiments whether or not explicitlydescribed. After reading the description, it will be apparent to oneskilled in the relevant art(s) how to implement the disclosure inalternative embodiments.

Furthermore, no element, component, or method step in the presentdisclosure is intended to be dedicated to the public regardless ofwhether the element, component, or method step is explicitly recited inthe claims. No claim element herein is to be construed under theprovisions of 35 U.S.C. 112(f) unless the element is expressly recitedusing the phrase “means for.” As used herein, the terms “comprises”,“comprising”, or any other variation thereof, are intended to cover anon-exclusive inclusion, such that a process, method, article, orapparatus that comprises a list of elements does not include only thoseelements but may include other elements not expressly listed or inherentto such process, method, article, or apparatus.

What is claimed is:
 1. A thermal management system for a vehicle,comprising: an electric power source loop comprising at least onebattery; and a heating component thermally coupled to the electric powersource loop, wherein, when an ambient temperature is less than a firstthreshold, the heating component pre-heats the at least one battery. 2.The thermal management system of claim 1, wherein the first threshold isless than 15 degrees Celsius.
 3. The thermal management system of claim1, further comprising a first valve, wherein when the ambienttemperature is less than the first threshold, the first valve thermallycouples the heating component and the electric power source loop.
 4. Thethermal management system of claim 1, wherein the heating componentcomprises at least one brake resistor.
 5. The thermal management systemof claim 3, wherein the first valve is a 4-way valve.
 6. The thermalmanagement system of claim 4, further comprising: a brake resistor loop,wherein the brake resistor loop comprises the at least one brakeresistor; and a shut-off valve, wherein the shut-off valve is coupled tothe electric power source loop and the brake resistor loop, wherein,when the ambient temperature is less than the first threshold, theshut-off valve thermally couples the electric power source loop to thebrake resistor loop and the first valve thermally couples the brakeresistor loop to the electric power source loop to pre-heat the at leastone battery.
 7. The thermal management system of claim 6, furthercomprising: an alternate cooling system thermally coupled to theelectric power source loop, wherein, when the brake resistor loop andthe electric power source loop are in operation at the same time, thealternate cooling system absorbs heat generated by the electric powersource loop.
 8. The thermal management system of claim 7, wherein thealternate cooling system comprises a refrigeration system.
 9. Thethermal management system of claim 1, wherein the electric power sourceloop comprises at least three batteries.
 10. The thermal managementsystem of claim 9, wherein each battery is thermally coupled in parallelwith the other at least two batteries.
 11. The thermal management systemof claim 1, wherein the heating component comprises an auxiliary heater.12. A method of increasing thermal efficiency in a thermal managementsystem of a vehicle, the method comprising: determining if an ambienttemperature of one or more batteries in an electric power source loop isless than a first threshold; and when the ambient temperature is lessthan the first threshold, pre-heating the one or more batteries.
 13. Themethod of claim 12, wherein the first threshold is less than 15 degreesCelsius.
 14. The method of claim 12, wherein pre-heating the one or morebatteries further comprises utilizing a heater to pre-heat the one ormore batteries.
 15. The method of claim 12, wherein pre-heating the oneor more batteries further comprises utilizing a brake resistor topre-heat the one or more batteries.
 16. The method of claim 15, whereinutilizing the brake resistor to pre-heat one or more batteries furthercomprises: circulating a coolant flowing from the electric power sourceloop through the brake resistor to heat the coolant; and circulating theheated coolant back through the electric power source loop.
 17. Themethod of claim 12, wherein when the ambient temperature is greater thanthe first threshold, the method further comprises: determining if abrake resistor comprised within the vehicle is in operation, wherein thevehicle further comprises a common radiator; when the brake resistor isin operation, utilizing the common radiator to cool the brake resistor;and when the brake resistor is not in operation, utilizing the commonradiator to cool the one or more batteries.
 18. The method of claim 17,wherein responsive to determination that the brake resistor is inoperation, the method further comprises: determining if the one or morebatteries are in operation; and when the one or more batteries are inoperation, utilizing an alternate cooling system to cool the one or morebatteries.
 19. A vehicle comprising: a brake resistor; and one or morebattery packs coupled to the brake resistor; wherein, when ambienttemperature is less than a first threshold, the brake resistor isconfigured to pre-heat at least one of the one or more battery packs.20. The vehicle of claim 19, wherein the first threshold is less than 15degrees Celsius.